US Air Force develops reinforced ceramics 3D printed sensors

The US Air Force has been incorporating additive manufacturing technologies in its operations for quite a while now. For instance, it has already collaborated with GE Additive to facilitate the adoption of metal 3D printing. This time US Air Force was interested in innovative materials to fabricate 3D printed sensors, that would have better properties than traditional materials. For this purpose, they have partnered with Florida State University for a dedicated research program. The project was successful and led to the development of 3D printed reinforced ceramics sensors.

Conventional 3D printing with ceramics

The research started a few years ago, in 2016, and has mainly focused on materials solutions for high-temperature sensors and diagnostics. It was led by Dr. Amanda Schrand, from AFRL’s Munitions Directorate, and Dr. Cheryl Xu, Associate Professor at Florida State University who recently relocated to North Carolina State University. “This is a great enhancement to the powder material used in 3D printing,” claims Dr. Xu. “The liquid polymer lends itself to many different, more advanced uses. 3D printing of liquid polymer precursors allows for the creation of complex shapes and honeycomb cellular architectures.”

The scientists used liquid preceramic polymers, which are a special class of polymers that can convert into ceramic materials, also known as polymer-derived ceramics (PDCs). This conversion occurs after a special high-temperature treatment, called pyrolysis.